Automatic control method and system for a reactor discharge process

Abstract

This application relates to the field of industrial control system technology, and discloses an automatic control method and system for the discharge process of a reactor. The method includes: acquiring material viscosity data, valve opening change data, and pipeline flow data to determine viscosity deviation values ​​and flow rate instability indicators; when the flow rate is unstable, determining a speed runaway risk coefficient by combining pressure interference data and temperature interference data; adjusting valve opening parameters according to the speed runaway risk coefficient and monitoring changes in material distribution density; further determining the material accumulation rate, overflow critical pressure, and blockage overflow prevention status; updating the discharge control parameters according to the blockage overflow prevention status, and outputting a stable discharge speed control result. This application can improve the stability and safety of the reactor discharge process.

Description

Technical Field

[0001] This application relates to the field of industrial control system technology, and more specifically, to an automatic control method and system for the discharge process of a reactor. Background Technology

[0002] In chemical production processes, the discharge of materials from reactors typically requires the stable transport of materials from the reactor to downstream receiving containers or subsequent processing stations via discharge pipelines. The smoothness of the discharge process not only affects the production cycle of a single batch but also the connection of subsequent processes, safety control, and product consistency. Therefore, reactor discharge control has always been a crucial aspect of industrial control systems.

[0003] In existing reactor discharge control methods, the discharge process is usually adjusted based on preset valve opening, single flow detection results, or human experience. This method can complete basic discharge when the material state changes little and the discharge environment is relatively stable. However, in actual production, the viscosity of different batches of materials may change, and the corresponding flow response after valve action may also differ. Adjusting based solely on a fixed opening or a single flow result makes it difficult to accurately reflect whether the current discharge state has deviated from the stable operating condition.

[0004] Furthermore, existing technologies typically lack continuous analysis of the relationship between material viscosity deviation, valve opening changes, and pipeline flow rate changes. When material viscosity increases, flow rate fluctuations increase, or flow rate continues to decrease, existing methods often only observe surface flow anomalies but cannot further transform such anomalies into effective judgments of the stability of the current discharge flow rate. This results in a processing interruption between the discharge anomaly identification stage and the subsequent control stage.

[0005] Meanwhile, during the discharge process, changes in pressure and temperature inside the reactor can disturb the flow of materials. Especially when the flow rate is already unstable, if the impact of abnormal pressure changes and temperature response lag on the current discharge process cannot be identified, subsequent valve adjustments will likely remain at the level of experience-based corrections, making it difficult to form targeted adjustment criteria based on the current operating conditions, thus affecting the accuracy and stability of discharge control.

[0006] Furthermore, existing technologies typically lack further tracking of the material distribution within the discharge pipeline after valve opening adjustments, and also lack joint judgment on local accumulation trends and overflow risks. In other words, existing technologies often only make local judgments based on a single flow rate or a single pressure, and cannot further transform the discharge results after valve adjustment into a comprehensive result of material accumulation and overflow trends. Therefore, it is also difficult to continue to update the discharge control parameters in a targeted manner, resulting in the entire discharge process lacking continuous convergence closed-loop control capabilities.

[0007] For example, during the discharge of high-viscosity materials, if the operator notices a decrease in flow rate and directly increases the valve opening, although the flow rate may change in a localized period, if the pressure inside the reactor increases simultaneously, or if material has already accumulated locally in the discharge pipeline, simply increasing the valve opening will not guarantee that the discharge process will return to stability. On the contrary, it may worsen the stagnation in the pipeline, or even cause the local pressure to approach the overflow boundary, increasing the risk of blockage or overflow.

[0008] Therefore, the technical problem that the existing technology urgently needs to solve is: how to continuously identify the current discharge status during the discharge process of the reactor in response to changes in material viscosity, unstable flow rate, and the influence of environmental disturbances, and further update the discharge control parameters based on the blockage trend and overflow trend, so as to achieve stable control of the reactor discharge process. Summary of the Invention

[0009] In order to overcome the above-mentioned defects of the prior art and to achieve the above objectives, this application provides the following technical solution: In the first aspect, this application discloses an automatic control method for the discharge process of a reactor, comprising: Acquire material viscosity data, valve opening change data, and reactor discharge pipeline flow data collected by sensors inside the reactor. Compare the material viscosity data with the preset viscosity range to determine the viscosity deviation value. Based on viscosity deviation values, valve opening change data, and flow fluctuation and flow decrease in pipeline flow data, analyze the stability of material flow velocity and determine the flow velocity instability index. When the flow rate instability index is higher than the preset threshold, pressure interference data and temperature interference data collected by the reactor environment sensor are acquired. Based on the pressure interference data, the characteristics of abnormal pressure change are determined. Based on the temperature interference data, the characteristics of temperature response delay and stabilization time are determined. Based on the characteristics of abnormal pressure change, temperature response delay and stabilization time, the risk coefficient of speed runaway is calculated. Based on the speed runaway risk coefficient, pressure abnormal change characteristics, and temperature response delay characteristics, the valve opening parameters are dynamically adjusted to obtain the adjusted valve opening value, and the changes in material distribution density in the pipeline are monitored. Based on the adjusted valve opening value and material distribution density changes, the discharge flow rate is monitored in real time, and the material accumulation rate is determined based on the discharge flow rate. The overflow critical pressure is determined based on the structural parameters of the reactor discharge pipeline and the material properties. The blockage and overflow prevention status is determined based on the material accumulation rate and the overflow critical pressure. The discharge control parameters are updated based on the blockage and overflow prevention status, and the discharge adjustment is continuously performed based on the updated discharge control parameters to output a stable discharge speed control result.

[0010] Secondly, this application discloses an automatic control system for the discharge process of a reactor, comprising: The deviation determination module is used to acquire material viscosity data, valve opening change data and pipeline flow data collected by sensors inside the reactor and the reactor discharge pipeline, and compare the material viscosity data with the preset viscosity range to determine the viscosity deviation value. The instability determination module is used to analyze the stability of material flow velocity and determine the instability index based on viscosity deviation value, valve opening change data and flow fluctuation amplitude and flow decrease amplitude in pipeline flow data. The risk assessment module is used to acquire pressure and temperature interference data collected by environmental sensors in the reactor when the flow rate instability index exceeds a preset threshold. Based on the pressure interference data, it determines the characteristics of abnormal pressure changes, and based on the temperature interference data, it determines the characteristics of temperature response delay and stabilization time. Based on the characteristics of abnormal pressure changes, temperature response delay and stabilization time, it calculates the risk coefficient of speed runaway. The valve opening adjustment module is used to dynamically adjust the valve opening parameters based on the speed runaway risk coefficient, pressure abnormal change characteristics, and temperature response delay characteristics, to obtain the adjusted valve opening value and monitor the changes in material distribution density in the pipeline. The prevention and judgment module is used to monitor the discharge flow rate in real time based on the adjusted valve opening value and the change in material distribution density, determine the material accumulation rate based on the discharge flow rate, determine the overflow critical pressure based on the structural parameters of the reactor discharge pipeline and the material properties, and determine the blockage and overflow prevention status based on the material accumulation rate and the overflow critical pressure. The control update module is used to update the discharge control parameters according to the blockage and overflow prevention status, and continuously perform discharge adjustment based on the updated discharge control parameters to output a stable discharge speed control result.

[0011] Compared with related technologies, this application has the following advantages: Compared with existing technologies, this application has the following advantages: This application first acquires material viscosity data, valve opening change data, and pipeline flow data. The material viscosity data is compared with a preset viscosity range to determine the viscosity deviation value. Then, based on the viscosity deviation value, flow fluctuation amplitude, and flow drop amplitude, the flow rate instability index is determined. When the flow rate instability index is higher than a preset threshold, pressure interference data and temperature interference data are further acquired. Pressure abnormal change characteristics, temperature response delay characteristics, and stabilization time are extracted, and the velocity runaway risk coefficient is calculated. Then, based on the velocity runaway risk coefficient, pressure abnormal change characteristics, and temperature response delay characteristics, the valve opening parameters are dynamically adjusted. Combined with changes in material distribution density, the material accumulation rate and overflow critical pressure are determined, thereby determining the blockage and overflow prevention status. Finally, the discharge control parameters are updated based on the blockage and overflow prevention status, and discharge adjustment is continuously executed, thus forming a continuous processing chain from anomaly identification, risk assessment, status determination to parameter update, improving the stability, safety, and control consistency of the reactor discharge process.

[0012] This application determines the viscosity deviation value by comparing the material viscosity data with the preset viscosity range, and determines the flow rate instability index by combining the valve opening change data and the flow fluctuation amplitude and flow rate decrease amplitude in the pipeline flow data. This makes the discharge control no longer rely solely on a single flow value or preset valve opening for judgment, but can jointly identify whether there is an unstable trend in the current discharge process from both the material state and the flow state, thereby improving the accuracy of discharge anomaly identification.

[0013] When the flow rate instability index exceeds a preset threshold, this application further determines the abnormal pressure change characteristics based on pressure disturbance data, determines the temperature response delay characteristics and stabilization time based on temperature disturbance data, and calculates the speed runaway risk coefficient on this basis, so that the environmental disturbance inside the reactor can be transformed into a quantifiable risk assessment result, thereby improving the correspondence between subsequent valve adjustment and the current operating condition and reducing the control deviation caused by adjustment based solely on experience.

[0014] This application dynamically adjusts the valve opening parameters based on the speed runaway risk coefficient, pressure abnormal change characteristics, and temperature response delay characteristics to obtain the adjusted valve opening value. It also monitors the changes in material distribution density in the pipeline, so that the valve opening adjustment can not only correct the current unstable state of material discharge, but also continue to track the changes in material distribution after adjustment. This provides a direct basis for subsequent judgment of local aggregation, local accumulation, and flow obstruction, thereby improving the stability of the material discharge adjustment process.

[0015] This application monitors the discharge flow rate in real time based on the adjusted valve opening value and changes in material distribution density, determines the material accumulation rate based on the discharge flow rate, determines the overflow critical pressure based on the structural parameters of the reactor discharge pipeline and material properties, and then determines the blockage and overflow prevention status based on the material accumulation rate and overflow critical pressure. This allows the current solution to simultaneously assess both blockage and overflow risks, avoiding the problem of local control based solely on a single flow rate or pressure in existing technologies, and improving the safety and reliability of the discharge process.

[0016] This application updates the discharge control parameters based on the blockage and overflow prevention status, and continuously performs discharge adjustment based on the updated discharge control parameters until a stable discharge speed control result is output. This allows the front-end status identification results to continue to affect the subsequent control parameter updates, forming a closed-loop adjustment process for the entire discharge process of the reactor, thereby improving the continuity, stability, and adaptability of discharge control under different material characteristics and different operating conditions. Attached Figure Description

[0017] Figure 1 A schematic flowchart of an automatic control method for the discharge process of a reactor provided in this application; Figure 2 This application provides a schematic diagram of an automatic control system module for the discharge process of a reactor. Detailed Implementation

[0018] The technical solutions of the embodiments of this application will be clearly and completely described below with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of this application, and not all embodiments. Based on the embodiments of this application, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of this application.

[0019] Example 1 Please see Figure 1 As shown, this embodiment provides an automatic control method for the discharge process of a reactor, including the following steps: In some implementations, material viscosity data, valve opening change data, and flow rate data from the reactor discharge pipe are acquired by sensors inside the reactor. The material viscosity data is then compared with a preset viscosity range to determine the viscosity deviation value. The implementation steps include: Step 1011: Set a fixed analysis window. The fixed analysis window is a time window with a constant length during the continuous feeding process. The length of the window is determined by the feeding adjustment cycle of the reactor, the mechanical response time of the valve actuator, and the refresh cycle of the flow sensor. In some embodiments, the fixed analysis window is 30 seconds and slides once every 5 seconds to ensure that the data in the same window can reflect the current feeding status without obscuring instantaneous changes due to the excessive length of the window.

[0020] Step 1012: Within the current fixed analysis window, retrieve multiple viscosity sampling values ​​output by the viscosity sensor inside the reactor to form material viscosity data; retrieve multiple valve opening sampling values ​​output by the valve position feedback device; retrieve multiple flow sampling values ​​output by the flow sensor installed on the reactor discharge pipe. The flow sensor can be an electromagnetic flowmeter, a mass flowmeter, or a differential pressure flowmeter; the valve position feedback device outputs the opening percentage value corresponding to the valve core position.

[0021] Step 1013: Perform validity screening on multiple viscosity sampling values, multiple valve opening sampling values, and multiple flow sampling values ​​within the current fixed analysis window. Validity screening includes: deleting data items that exceed the sensor's range, deleting data items missing at the sampling time, and deleting data items whose continuous jumps exceed a preset multiple of the previous sampling value. The preset multiple is determined based on the sensor's accuracy and the device's allowable rate of change, and is used to exclude isolated outliers caused by sampling failures.

[0022] Step 1014: Calculate the window representative value for multiple viscosity sample values ​​that have passed the validity screening to obtain the window viscosity value corresponding to the current fixed analysis window; the window representative value is calculated using the extreme value removal averaging method, that is, first delete the maximum and minimum viscosity sample values ​​in the current fixed analysis window, and then average the remaining viscosity sample values ​​to reduce the impact of occasional noise on the results.

[0023] Step 1015: Sort the multiple valve opening sample values ​​that have passed the validity screening according to the sampling time, and perform a difference operation on two adjacent valve opening sample values ​​to obtain the opening change amount; then divide the opening change amount by the corresponding sampling time interval to obtain the opening change rate; combine each opening change amount and each opening change rate in time order to form valve opening change data; the valve opening change data includes at least the total opening change amount, average opening change rate and opening change direction within the current fixed analysis window.

[0024] Step 1016: Sort the multiple flow sampling values ​​that have passed the validity screening according to the sampling time to form the pipeline flow data of the reactor discharge pipeline; the reactor discharge pipeline is the discharge pipeline that connects the bottom or side of the reactor to the subsequent collection container, buffer container or downstream conveying pipeline; the pipeline flow data maintains a time reference consistent with the window viscosity value and valve opening change data.

[0025] Step 1017: Construct a preset viscosity range. The preset viscosity range is formed as follows: First, read the target viscosity range in the process file corresponding to the target material; then, read the viscosity distribution of historical qualified batches within the current discharge temperature range; then, read the maximum allowable viscosity of the reactor discharge pipeline under the current valve specifications and current discharge stage; then, based on the target viscosity range in the process file, using the viscosity distribution of historical qualified batches as the correction boundary, and using the maximum allowable viscosity of the reactor discharge pipeline as the upper limit constraint, obtain the preset viscosity range corresponding to the current fixed analysis window; thereby ensuring that the preset viscosity range matches the current material type, current discharge temperature, and current discharge pipeline capacity.

[0026] Step 1018: Compare the window viscosity value with the preset viscosity range; when the window viscosity value is within the preset viscosity range, the viscosity deviation value is set to 0; when the window viscosity value is higher than the upper limit of the preset viscosity range, subtract the upper limit of the preset viscosity range from the window viscosity value to obtain a positive viscosity deviation value; when the window viscosity value is lower than the lower limit of the preset viscosity range, subtract the lower limit of the preset viscosity range from the window viscosity value to obtain a negative viscosity deviation value; the viscosity deviation value retains a positive or negative sign to distinguish between high and low operating conditions.

[0027] Step 1019: Output the viscosity deviation value, valve opening change data, and pipeline flow data of the reactor discharge pipe to the next step to analyze the stability of material flow rate and determine the flow rate instability index.

[0028] In some implementations, to illustrate the process of determining the viscosity deviation value, the viscosity sample values ​​after validity screening within the current fixed analysis window can be 1180 mPa·s, 1200 mPa·s, 1210 mPa·s, 1190 mPa·s, and 1220 mPa·s. First, the maximum viscosity sample value of 1220 mPa·s and the minimum viscosity sample value of 1180 mPa·s are removed, and then the remaining viscosity sample values ​​are averaged to obtain a window viscosity value of 1200 mPa·s. Under the current discharge temperature range, the target viscosity range in the corresponding process file for the target material can be 1050 mPa·s to 1120 mPa·s. The viscosity distribution correction boundary for historical qualified batches within the current discharge temperature range can be 1060 mPa·s to 1140 mPa·s. The maximum allowable viscosity through the reactor discharge pipe under the current valve specifications and discharge stage can be 1150 mPa·s. Therefore, the preset viscosity range corresponding to the current fixed analysis window can be determined to be 1060 mPa·s to 1150 mPa·s. Since the window viscosity value of 1200 mPa·s is higher than the upper limit of the preset viscosity range of 1150 mPa·s, 1150 mPa·s is subtracted from 1200 mPa·s to obtain a positive viscosity deviation value of 50 mPa·s. This positive viscosity deviation value is then output to the next step for subsequent determination of flow rate instability indicators.

[0029] In some implementations, the stability of material flow velocity is analyzed based on viscosity deviation values, valve opening change data, and flow fluctuation and decrease amplitudes in pipeline flow data to determine flow velocity instability indicators. The purpose is to convert viscosity deviation values, valve opening change data, and pipeline flow data from the reactor discharge pipeline into a quantitative judgment of whether the current discharge flow velocity is stable, and to output flow velocity instability indicators that can directly trigger subsequent environmental interference analysis. The implementation steps include: Step 2011: Read the viscosity deviation value, valve opening change data and reactor discharge pipeline flow data, and arrange the multiple flow sampling values ​​in the current fixed analysis window in time order to form a flow time series sequence.

[0030] Step 2012: Calculate the effective cross-sectional area of ​​the discharge pipe based on the inner diameter of the discharge pipe of the reactor, and then divide each flow sampling value in the flow time series by the effective cross-sectional area to obtain the flow velocity time series; if the flow sensor directly outputs the mass flow rate, then first convert it into volume flow rate based on the current material density, and then calculate the flow velocity; thus, the subsequent analysis object is unified as the discharge flow velocity.

[0031] Step 2013: Determine the flow fluctuation amplitude based on the flow time series. The flow fluctuation amplitude is determined by the difference between the maximum and minimum flow sampling values ​​within the current fixed analysis window. In some implementations, the flow standard deviation can also be calculated simultaneously, and the maximum and minimum difference can be used together with the flow standard deviation as components of the flow fluctuation amplitude. The larger the flow fluctuation amplitude, the more unstable the material flow rate within the current fixed analysis window.

[0032] Step 2014: Determine the flow rate decrease based on the flow time series. First, determine the baseline flow rate value. The baseline flow rate value is formed as follows: Read the target discharge flow rate set for the current material in the process, and read the average flow rate value of the three most recent consecutive stable discharge windows. When the deviation between the three values ​​is within the preset allowable range, take the target discharge flow rate set in the process as the baseline flow rate value. When the deviation exceeds the preset allowable range, take the average flow rate value of the three most recent consecutive stable discharge windows as the baseline flow rate value. Then, subtract the average flow rate value in the current fixed analysis window from the baseline flow rate value, and then divide by the baseline flow rate value to obtain the flow rate decrease.

[0033] Step 2015: Establish the response correspondence between valve opening change data and flow rate time sequence; specifically: read the action delay time range in the valve actuator specification file, and read the actual time difference distribution from valve opening change to flow rate change in historical qualified discharge records, and determine the preset response time difference interval based on the overlap interval of the two; then determine whether the flow rate time sequence shows a corresponding change within the preset response time difference interval after the valve opening change in the current fixed analysis window; if it does, it is determined that the current valve adjustment and the discharge flow rate change have a response correspondence; if it does not, it is determined that the current valve adjustment and the discharge flow rate change do not have a response correspondence.

[0034] Step 2016: Normalize the viscosity deviation value, flow fluctuation amplitude, and flow drop amplitude. The normalized result of the viscosity deviation value is equal to the absolute value of the viscosity deviation divided by the preset viscosity range width. The normalized result of the flow fluctuation amplitude is equal to the flow fluctuation amplitude divided by the reference flow value. The flow drop amplitude itself is a proportional value and is directly used as the normalization result. The purpose of normalization is to unify the characteristics of different dimensions under the same dimension that can be weighted and combined.

[0035] Step 2017: Construct the flow rate instability level. First, extract the influence ratios of viscosity deviation, flow fluctuation, and flow rate decrease on flow rate instability from historical qualified discharge records and historical abnormal discharge records to form viscosity deviation weight, flow fluctuation weight, and flow rate decrease weight. Then, multiply the normalized viscosity deviation value, normalized flow fluctuation amplitude, and normalized flow rate decrease amplitude by their respective weights and sum them to obtain the initial flow rate instability level. If step 2015 determines that valve adjustment and discharge flow rate change do not have a responsive correspondence, then add a preset mismatch compensation amount to the initial flow rate instability level to obtain the final flow rate instability level. The preset mismatch compensation amount is determined based on the average additional risk when valve opening change and flow rate change mismatch occur in historical abnormal discharge records.

[0036] Step 2018: Construct a flow rate instability judgment threshold. The flow rate instability judgment threshold is determined jointly based on the upper quantile of the flow rate instability in historical qualified material discharge records, the lower quantile of the flow rate instability in historical abnormal material discharge records, and the safety margin. The safety margin is used to avoid the working condition near the qualified boundary being misjudged as stable.

[0037] Step 2019: Compare the final flow velocity instability level with the flow velocity instability judgment threshold; when the final flow velocity instability level is less than the flow velocity instability judgment threshold, determine the flow velocity instability index as 0; when the final flow velocity instability level is greater than or equal to the flow velocity instability judgment threshold, determine the flow velocity instability index as 1; the flow velocity instability index adopts a binary triggering form.

[0038] Step 2020: Output the flow rate instability index to the next step; only when the flow rate instability index is 1, start the reactor environment sensor data acquisition and feature extraction process.

[0039] For example, to illustrate the process of determining the flow rate instability index, the preset viscosity range width can be 90 mPa·s, and the absolute value of the viscosity deviation obtained in step 1018 can be 50 mPa·s. Therefore, the normalized viscosity deviation value can be 50 ÷ 90 = 0.556. The maximum flow rate sampling value within the current fixed analysis window can be 2.10 cubic meters per hour, and the minimum flow rate sampling value can be 1.70 cubic meters per hour. Therefore, the flow rate fluctuation range can be 0.40 cubic meters per hour. The baseline flow rate value can be 2.00 cubic meters per hour, so the normalized flow rate fluctuation range can be 0.40 ÷ 2.00 = 0.20. The average flow rate value within the current fixed analysis window can be 1.80 cubic meters per hour, so the flow rate decrease can be (2.00 - 1.80) ÷ 2.00 = 0.10. If the viscosity deviation weight, flow rate fluctuation weight, and flow rate decrease weight are 0.35, 0.40, and 0.25 respectively, then the initial flow rate instability can be 0.556×0.35+0.20×0.40+0.10×0.25=0.2996. If step 2015 determines that the valve adjustment and the change in discharge flow rate do not have a corresponding response, and the preset mismatch compensation amount can be 0.08, then the final flow rate instability can be 0.3796. If the flow rate instability judgment threshold can be 0.32, then since the final flow rate instability is greater than the flow rate instability judgment threshold, the flow rate instability index is determined to be 1, and the subsequent environmental interference feature extraction process is triggered.

[0040] In some implementations, when the flow rate instability index exceeds a preset threshold, pressure and temperature disturbance data collected by environmental sensors in the reactor are acquired. Pressure anomaly change characteristics are determined based on the pressure disturbance data, and temperature response delay characteristics and stabilization time are determined based on the temperature disturbance data. The purpose is to further identify the degree of disturbance to the discharge process caused by changes in the reactor environment when the current discharge flow rate already shows signs of instability, and to generate pressure anomaly change characteristics, temperature response delay characteristics, and stabilization time that can be directly used for risk calculation. The implementation steps include: Step 3011: When the flow rate instability index is 1, an environmental analysis window is established. The start time of the environmental analysis window is the moment when the flow rate instability index is set to 1 within the current fixed analysis window, and the end time is the moment corresponding to a preset analysis duration after that moment; the preset analysis duration is determined jointly based on the average lag time of pressure change affecting flow rate and the average lag time of temperature change affecting viscosity.

[0041] Step 3012: In the environmental analysis window, multiple pressure sampling values ​​output by the reactor pressure sensor are called to form pressure interference data; multiple temperature sampling values ​​output by the reactor temperature sensor are called to form temperature interference data; the pressure interference data and temperature interference data adopt the same time base as the above steps so that they can be time-aligned with the valve opening change data in the future.

[0042] Step 3013: Construct a pressure baseline; the pressure baseline is determined by the average pressure value within three consecutive stable windows before the flow rate instability index is triggered; if the current discharge stage changes, the reference pressure value pre-calibrated for the corresponding discharge stage is used instead; thereby ensuring that the pressure baseline is consistent with the current discharge stage.

[0043] Step 3014: Subtract the pressure baseline from each pressure sample value in the pressure disturbance data to obtain each pressure deviation; then perform differential calculation on two adjacent pressure sample values ​​and divide by the sampling interval to obtain each pressure change rate; the pressure deviation is used to characterize the degree of deviation of the current pressure relative to the stable operating condition, and the pressure change rate is used to characterize the degree of sudden change of pressure in a short period of time.

[0044] Step 3015: Construct pressure anomaly judgment conditions; the pressure anomaly judgment conditions include pressure deviation threshold and pressure change rate threshold; the pressure deviation threshold is determined based on a preset multiple of the standard deviation of pressure deviation within the stable window; the pressure change rate threshold is determined jointly based on the average change rate of pressure abrupt segment in historical abnormal material discharge records and the safety correction amount; the safety correction amount is determined based on the equipment's allowable pressure change capability.

[0045] Step 3016: Compare each pressure deviation with the pressure deviation threshold, and compare each pressure change rate with the pressure change rate threshold; when the pressure deviation at a certain sampling time is greater than or equal to the pressure deviation threshold, or the pressure change rate at that sampling time is greater than or equal to the pressure change rate threshold, mark that sampling time as a pressure anomaly point.

[0046] Step 3017: Merge consecutive pressure anomaly points into pressure anomaly segments; for cases where the time interval between two adjacent pressure anomaly points is less than the preset merging interval, they are also merged into the same pressure anomaly segment; the preset merging interval is determined based on the pressure sensor refresh cycle and valve adjustment cycle, in order to avoid the same abnormal event being split into multiple isolated segments.

[0047] Step 3018: Determine the pressure anomaly mutation characteristics based on the pressure anomaly segment; the pressure anomaly mutation characteristics include at least the pressure anomaly start time, pressure anomaly amplitude, and pressure anomaly duration; wherein, the pressure anomaly start time is the initial sampling time of the pressure anomaly segment; the pressure anomaly amplitude is the difference between the maximum pressure sampling value within the pressure anomaly segment and the pressure baseline; the pressure anomaly duration is the time difference between the pressure anomaly segment termination time and the start time; if multiple pressure anomaly segments exist within the environmental analysis window, the result corresponding to the pressure anomaly segment with the largest pressure anomaly amplitude is taken as the pressure anomaly mutation characteristic of the current environmental analysis window.

[0048] Step 3019: Construct a temperature baseline; the temperature baseline is determined by the average temperature value within three consecutive stable windows before the flow rate instability index is triggered; if the current feeding stage is switched, the reference temperature value pre-calibrated for the corresponding feeding stage is used instead.

[0049] Step 3010: Read the valve opening change data and determine the starting time of the opening change from the valve opening change data; the starting time of the opening change is defined as the sampling time when the absolute value of the first opening change in the current fixed analysis window is greater than or equal to the opening change starting threshold; the opening change starting threshold is determined based on the valve position feedback device resolution and the minimum effective action amount of the valve.

[0050] Step 3011: Subtract the temperature baseline from each temperature sample value in the temperature interference data to obtain the temperature offset; determine the first sampling time when two or more consecutive temperature offsets are greater than or equal to the temperature response judgment threshold as the temperature response start time; the temperature response judgment threshold is determined jointly based on the accuracy of the temperature sensor, the accuracy of temperature control execution, and the sensitivity of the target material to temperature changes.

[0051] Step 3012: The time difference between the start time of the temperature response and the start time of the opening change is determined as the temperature response delay value; if there are multiple temperature response events within the environmental analysis window, the average of the multiple temperature response delay values ​​is calculated to obtain the temperature response delay characteristics of the current environmental analysis window; thereby avoiding the distortion of results caused by a single occasional temperature fluctuation.

[0052] Step 3013: Construct a stable temperature range. The stable temperature range is determined based on the allowable temperature fluctuation range of the target material, the temperature control requirements of the current feeding stage, and the measurement error of the temperature sensor. Then, search the environmental analysis window for the longest continuous time period in which the temperature sampling value is continuously within the stable temperature range, and determine the length of this longest continuous time period as the stable duration.

[0053] Step 3014: Output the abnormal pressure change characteristics, temperature response delay characteristics, and stabilization time to the next step, which will be used to calculate the speed runaway risk coefficient.

[0054] In some implementations, the purpose of calculating the speed runaway risk coefficient based on the characteristics of abnormal pressure changes, temperature response delays, and stabilization time is to convert these characteristics into a speed runaway risk coefficient with unified dimensions, thus providing a clear quantitative basis for subsequent valve opening parameter adjustments. The implementation steps include: Step 4011: Read the abnormal pressure change characteristics, temperature response delay characteristics, and stabilization duration, and extract the abnormal pressure amplitude, abnormal pressure duration, temperature response delay value, and stabilization duration value as the raw quantities for risk calculation.

[0055] Step 4012: Normalize the abnormal pressure amplitude to obtain the amplitude risk quantity; specifically: divide the abnormal pressure amplitude by the upper limit of allowable pressure fluctuation corresponding to the current discharge stage to obtain the amplitude risk quantity; the upper limit of allowable pressure fluctuation is determined based on the allowable pressure fluctuation range of the reactor design and the pressure fluctuation distribution in the historical qualified discharge records.

[0056] Step 4013: Normalize the duration of the pressure anomaly to obtain the sustained risk quantity; specifically, divide the duration of the pressure anomaly by the allowable duration benchmark for the pressure anomaly to obtain the sustained risk quantity. The allowable duration benchmark for the pressure anomaly is determined based on the short-term duration distribution of pressure anomalies in historical qualified material discharge records and the delay of equipment safety protection actions.

[0057] Step 4014: Calculate the pressure risk value based on the amplitude risk and the duration risk. Specifically, first read the amplitude weight and duration weight formed by the contribution ratio of the pressure anomaly amplitude and the pressure anomaly duration to the flow velocity instability in the historical abnormal material discharge records; then multiply the amplitude risk by the amplitude weight and the duration risk by the duration weight, and sum the two to obtain the pressure risk value.

[0058] Step 4015: Normalize the temperature response delay characteristics to obtain the temperature delay risk value; specifically: divide the temperature response delay value by the delay reference duration; the delay reference duration is determined based on the average time difference between the change in valve opening and the occurrence of temperature response in historical qualified material discharge records and the normal heat transfer duration of the temperature control system.

[0059] Step 4016: Perform reverse normalization on the stabilization time to obtain the temperature stability risk value; specifically: first read the stabilization reference time, then calculate the ratio of the current stabilization time to the stabilization reference time to obtain the temperature stability risk value; when the current stabilization time is greater than or equal to the stabilization reference time, the temperature stability risk value is limited to 0; the stabilization reference time is determined based on the average stabilization time in the historical qualified feeding records and the minimum time required to maintain stable feeding in the current feeding stage; the reason for using reverse normalization is that the shorter the stabilization time, the greater the risk of loss of control over the feeding speed.

[0060] Step 4017: Construct a calculation rule for the velocity runaway risk coefficient. The calculation rule is formed as follows: extract the correspondence between pressure risk value, temperature delay risk value, and temperature stability risk value and the degree of flow instability from historical material discharge records; based on the contribution ratio of the three to the change in the degree of flow instability, form pressure weight, temperature delay weight, and temperature stability weight; then multiply the pressure risk value by the pressure weight, multiply the temperature delay risk value by the temperature delay weight, multiply the temperature stability risk value by the temperature stability weight, and finally sum them to obtain the velocity runaway risk coefficient.

[0061] Step 4018: Limit the speed runaway risk coefficient to a certain range; if the calculation result is less than 0, the speed runaway risk coefficient is limited to 0; if the calculation result is greater than the preset maximum risk value, the speed runaway risk coefficient is limited to the preset maximum risk value; the preset maximum risk value is determined based on the maximum correction range allowed by the control system and the upper limit of equipment safety; by limiting the range, it is ensured that the subsequent valve opening parameter adjustment will not exceed the allowable range of the actuator due to abnormal calculation results.

[0062] Step 4019 outputs the speed runaway risk coefficient to the subsequent step of dynamically adjusting the valve opening parameters based on the speed runaway risk coefficient, pressure abnormal change characteristics, and temperature response delay characteristics; wherein, the speed runaway risk coefficient serves as the quantitative basis for the adjustment range, the pressure abnormal change characteristics serve as the basis for distinguishing whether to prioritize suppressing pressure shocks, and the temperature response delay characteristics serve as the basis for distinguishing whether to extend the adjustment observation period.

[0063] Furthermore, to illustrate the calculation process of the speed runaway risk coefficient, the pressure anomaly amplitude can be 18 kPa, and the allowable pressure fluctuation limit corresponding to the current discharge stage can be 30 kPa. Therefore, the amplitude risk can be 18 ÷ 30 = 0.60. The pressure anomaly duration can be 12 seconds, and the allowable duration baseline for pressure anomalies can be 20 seconds. Therefore, the duration risk can be 12 ÷ 20 = 0.60. If the amplitude weight and duration weight are 0.55 and 0.45 respectively, the pressure risk value can be 0.60 × 0.55 + 0.60 × 0.45 = 0.60. The temperature response delay value can be 15 seconds, and the delay baseline duration can be 10 seconds. Therefore, the temperature delay risk value can be 15 ÷ 10 = 1.50. The stabilization duration can be 18 seconds, and the stabilization baseline duration can be 30 seconds. Therefore, the temperature stabilization risk value can be 1 - 18 ÷ 30 = 0.40. If the pressure weight, temperature delay weight, and temperature stability weight are 0.45, 0.35, and 0.20 respectively, then the speed runaway risk coefficient can be 0.60×0.45+1.50×0.35+0.40×0.20=0.875. If the preset maximum risk value can be 1.00, then the speed runaway risk coefficient after the interval is limited is still 0.875, and this speed runaway risk coefficient is output to the subsequent dynamic adjustment step of valve opening parameters as a quantitative basis for the adjustment range.

[0064] In some implementations, the purpose of dynamically adjusting the valve opening parameters based on the speed runaway risk coefficient, pressure anomaly change characteristics, and temperature response delay characteristics to obtain the adjusted valve opening value, and monitoring the changes in material distribution density within the pipeline, is to convert the speed runaway risk coefficient, pressure anomaly change characteristics, and temperature response delay characteristics into directly executable valve opening correction values, thereby bringing the current discharge process back from an unstable state to a controlled state. Simultaneously, by monitoring the changes in material distribution density within the reactor discharge pipeline, it is determined whether local concentration, local accumulation, or uneven cross-sectional distribution occurs after the valve opening adjustment, providing input for determining the subsequent material accumulation rate. The implementation steps include: Step 5011: Read the speed runaway risk coefficient, and read the pressure abnormal change characteristics and temperature response delay characteristics; wherein, the pressure abnormal change characteristics include at least the pressure abnormality amplitude and the pressure abnormality duration, and the temperature response delay characteristics are the temperature response delay values ​​output in the above steps.

[0065] Step 5012: Read the actual valve opening value before adjustment and use it as the current valve opening reference value; the current actual valve opening value before adjustment is taken from the valve position feedback device at the end of the subsequent steps; when there is a delay in the action confirmation of the valve actuator, the actual valve opening value after the most recent action completion confirmation is used as the current valve opening reference value.

[0066] Step 5013: Construct the flow deviation; specifically: read the baseline flow value used to determine the flow rate decrease, then read the average flow value in the current analysis window, subtract the average flow value in the current analysis window from the baseline flow value to obtain the flow deviation; when the flow deviation is positive, it indicates that the current material feeding capacity is lower than the baseline level; when the flow deviation is negative or zero, it indicates that the current material feeding capacity is not lower than the baseline level.

[0067] Step 5014: Construct the valve opening adjustment direction determination condition; the determination condition is formed as follows: when the flow deviation is greater than zero and the abnormal pressure amplitude is less than the high pressure limit threshold, the valve opening adjustment direction is determined to be the increasing direction; when the flow deviation is less than or equal to zero, or the abnormal pressure amplitude is greater than or equal to the high pressure limit threshold, the valve opening adjustment direction is determined to be the decreasing direction; the high pressure limit threshold is determined based on the upper limit of the allowable pressure fluctuation of the reactor design, the high pressure change interval in the historical abnormal discharge record, and the single correction amplitude allowed by the valve actuator.

[0068] Step 5015: Construct the basic valve opening correction amount. Specifically, first, divide the velocity runaway risk coefficient into at least three risk segments: low risk, medium risk, and high risk. Then, configure a basic correction ratio range for each risk segment. Next, based on the risk segment where the current velocity runaway risk coefficient is located, determine the basic correction ratio within the corresponding basic correction ratio range using linear interpolation. Finally, multiply the basic correction ratio by the current valve opening reference value to obtain the basic opening correction amount. The basic correction ratio range corresponding to each risk segment is determined based on the statistical results of the valve opening correction ratio required to restore flow velocity stability under different risk levels in historical material discharge records.

[0069] Step 5016: Perform pressure correction on the basic opening correction amount; specifically: first, divide the pressure anomaly amplitude by the upper limit of allowable pressure fluctuation to obtain the pressure correction coefficient; then, based on the ratio of the pressure anomaly duration to the pressure duration benchmark, obtain the duration correction coefficient; then, multiply the basic opening correction amount by the pressure correction coefficient and the duration correction coefficient to obtain the pressure-corrected opening correction amount; the upper limit of allowable pressure fluctuation is determined according to the equipment design parameters, and the pressure duration benchmark is determined according to the distribution of pressure anomaly duration in the historical safe material discharge record; when the valve opening adjustment direction is decreasing, the pressure-corrected opening correction amount is directly used; when the valve opening adjustment direction is increasing, if the pressure correction coefficient is greater than the preset suppression threshold, the pressure-corrected opening correction amount is multiplied by the opening amount suppression coefficient to avoid continuing to rapidly open the valve under high pressure conditions.

[0070] Step 5017: Perform temperature delay correction on the pressure-corrected opening correction amount; specifically: divide the temperature response delay value by the temperature delay reference duration to obtain the delay ratio; when the delay ratio is greater than 1, it indicates that the temperature change responds slowly to the valve action, so divide the pressure-corrected opening correction amount by the delay ratio to obtain the delay-corrected opening correction amount; when the delay ratio is less than or equal to 1, retain the pressure-corrected opening correction amount unchanged; the temperature delay reference duration is determined based on the average time difference between valve action and temperature response in historical qualified material discharge records.

[0071] Step 5018: Calculate the adjusted valve opening value based on the current valve opening reference value, the valve opening adjustment direction, and the opening correction amount after delay correction. When the adjustment direction is increasing, use the current valve opening reference value plus the opening correction amount after delay correction. When the adjustment direction is decreasing, use the current valve opening reference value minus the opening correction amount after delay correction.

[0072] Step 5019: Apply boundary constraints to the adjusted valve opening value; the boundary constraints include a maximum opening constraint and a minimum opening constraint; the maximum opening constraint is determined based on the valve's maximum mechanical stroke, the maximum allowable discharge intensity during the current discharge stage, and the maximum allowable flow rate of the reactor discharge pipeline; the minimum opening constraint is determined based on the valve's minimum effective control opening, the minimum flow rate required to maintain continuous material discharge, and the minimum stable opening to prevent frequent valve opening and closing; the result after boundary constraints is taken as the final adjusted valve opening value.

[0073] As another example, to illustrate the formation process of the adjusted valve opening value, the current valve opening baseline value can be 42.0%, the average flow rate within the current analysis window can be 1.80 cubic meters per hour, and the baseline flow rate can be 2.00 cubic meters per hour, resulting in a flow deviation of 0.20 cubic meters per hour. The abnormal pressure amplitude can be 18 kPa, and the high-pressure limit threshold can be 25 kPa. Since the flow deviation is greater than 0 and the abnormal pressure amplitude is less than the high-pressure limit threshold, the valve opening adjustment direction can be determined to be the increasing direction. The current speed runaway risk coefficient can be 0.875, which is in the medium-risk range; the basic correction ratio range corresponding to the medium-risk range can be 10% to 14%. After linear interpolation, the basic correction ratio can be 12%, so the basic opening correction amount can be 42.0% × 12% = 5.04%. The allowable pressure fluctuation limit can be 30 kPa, and the pressure duration baseline can be 20 seconds. Therefore, the pressure correction factor can be 18 ÷ 30 = 0.60, and the duration correction factor can be 12 ÷ 20 = 0.60. Thus, the pressure-corrected opening correction amount can be 5.04% × 0.60 × 0.60 = 1.8144%. The temperature response delay value can be 15 seconds, and the temperature delay baseline duration can be 10 seconds. Therefore, the delay ratio can be 1.50, and the delay-corrected opening correction amount can be 1.8144% ÷ 1.50 = 1.2096%. Further, the adjusted valve opening value can be 42.0% + 1.2096% = 43.2096%. If the maximum opening limit can be 58.0%, and the minimum opening limit can be 18.0%, then the final adjusted valve opening value after boundary limits will still be 43.2096%, and this result will be sent to the valve actuator to maintain the valve opening value unchanged for the specified duration.

[0074] Step 5020: The final adjusted valve opening value is sent to the valve actuator, and the valve opening value is maintained unchanged for a holding time. The holding time is determined based on the temperature delay reference time, the valve actuator action completion time, and the flow sensor refresh cycle to ensure that the adjustment result can be fully observed in subsequent monitoring.

[0075] Step 5021: During the holding time, the ultrasonic measuring component installed on the outer wall of the discharge pipe of the reactor is invoked to collect sound propagation time data at at least two different axial positions and multiple circumferential angles at each axial position along the discharge pipe; then, according to the material density calibration curve, each sound propagation time data is converted into the local density value of the corresponding position; the material density calibration curve is pre-established based on the ultrasonic propagation time test data of the same material under different known density conditions.

[0076] Step 5022: Average the multiple local density values ​​at the same axial position to obtain the cross-sectional average density at that axial position; calculate the difference between the cross-sectional average densities at different axial positions to obtain the axial density difference; then perform differential processing on the cross-sectional average density corresponding to the same axial position within the current holding time and the cross-sectional average density corresponding to the same axial position within the immediately preceding holding time to obtain the cross-sectional density change at that axial position; average the cross-sectional density changes obtained at multiple axial positions to obtain the cross-sectional density change corresponding to the current holding time; perform differential processing on the density difference between two adjacent axial positions within the current holding time and the density difference between two identical axial positions within the immediately preceding holding time to obtain the axial density difference change for that position pair; average the axial density difference changes obtained for multiple position pairs to obtain the axial density difference change corresponding to the current holding time.

[0077] Step 5023: The change in cross-sectional density and the change in axial density difference are jointly determined as the change in material distribution density; wherein, the change in cross-sectional density is used to characterize whether the average density of the material within the same cross-section increases, and the change in axial density difference is used to characterize whether local concentration occurs along the length of the pipeline.

[0078] In some implementations, the discharge flow rate is monitored in real time based on the adjusted valve opening value and changes in material distribution density. The material accumulation rate is determined based on the discharge flow rate, and the overflow critical pressure is determined based on the structural parameters of the reactor discharge pipe and the material properties. The purpose is to monitor the discharge results in real time after the valve opening adjustment is completed, and to convert the current discharge flow rate and material distribution density changes into a material accumulation rate. Simultaneously, the overflow critical pressure under the current operating conditions is calculated based on the structural parameters of the reactor discharge pipe and the material properties, providing two direct input results for subsequent determination of the blockage and overflow prevention status. The implementation steps include: Step 6011: After the holding time in step 5020 ends, establish a post-adjustment monitoring window; the length of the post-adjustment monitoring window is determined based on the flow sensor refresh cycle, the valve actuator action completion time, and the average passage time of the material in the reactor discharge pipe.

[0079] Step 6012: In the adjusted monitoring window, call the flow sensor to output multiple flow sampling values ​​to form an adjusted flow sequence; then, based on the effective cross-sectional area of ​​the reactor discharge pipe, convert each flow sampling value in the adjusted flow sequence into an adjusted flow velocity sequence; the effective cross-sectional area is determined based on the pipe inner diameter or the equivalent area of ​​a non-circular cross section.

[0080] Step 6013: Average the adjusted flow rate sequence to obtain the real-time discharge flow rate; at the same time, calculate the maximum value, minimum value and standard deviation of the adjusted flow rate sequence as auxiliary characterization quantities of the real-time discharge flow rate, which are used to determine whether there are still significant fluctuations after the current valve opening is adjusted.

[0081] Step 6014, constructing a backlog reference flow rate; specifically: read the baseline flow rate value and convert it into a baseline flow rate; then read the average flow rate of the monitoring window after adjustment for the most recent three consecutive windows that have not triggered the blockage overflow prevention state; when the deviation between the above two is less than a preset deviation threshold, the baseline flow rate is taken as the backlog reference flow rate; when the deviation is greater than or equal to the preset deviation threshold, the average flow rate of the most recent three consecutive windows that have not triggered the blockage overflow prevention state is taken as the backlog reference flow rate; the preset deviation threshold is determined based on the process allowable flow rate deviation.

[0082] Step 6015: Calculate the flow velocity gap value; the flow velocity gap value is equal to the accumulation reference flow velocity minus the real-time discharge flow velocity; when the flow velocity gap value is negative, the flow velocity gap value is limited to 0 to avoid negative accumulation results when the flow velocity is higher than the reference value.

[0083] Step 6016: Construct a density aggregation coefficient based on the material distribution density change; specifically: divide the cross-sectional density change by the current average material density to obtain the cross-sectional aggregation ratio; divide the axial density difference change by the current average material density to obtain the axial aggregation ratio; then determine the cross-sectional aggregation weight and axial aggregation weight based on the influence ratio of cross-sectional aggregation and axial aggregation on the accumulation formation rate in the historical records before blockage; then sum the cross-sectional aggregation ratio and axial aggregation ratio by weight, and add 1 to the result to obtain the density aggregation coefficient; the reason for adding 1 is that when there is no obvious aggregation, the density aggregation coefficient still maintains the basic value of 1, and will not amplify the flow velocity gap value.

[0084] Step 6017: Determine the material accumulation rate based on the flow velocity gap value, the effective cross-sectional area of ​​the reactor discharge pipe, and the density aggregation coefficient; specifically: multiply the flow velocity gap value by the effective cross-sectional area of ​​the reactor discharge pipe to obtain the volume retention per unit time; then multiply the volume retention by the density aggregation coefficient to obtain the material accumulation rate; thus, the material accumulation rate simultaneously reflects the increased retention caused by the decrease in flow velocity and the enhanced local accumulation caused by density aggregation.

[0085] For example, to illustrate the process of determining the material accumulation rate, the real-time discharge velocity within the adjusted monitoring window can be 0.72 m / s, the accumulation reference velocity can be 0.90 m / s, and the velocity gap value can be 0.18 m / s. The current average material density can be 1.20 tons per cubic meter, and the average change in cross-sectional density obtained from multiple axial positions within the current holding time can be 0.06 tons per cubic meter. Therefore, the cross-sectional aggregation ratio can be 0.06 ÷ 1.20 = 0.05. Similarly, the average change in axial density difference obtained from multiple positions within the current holding time can also be 0.06 tons per cubic meter, so the axial aggregation ratio can be 0.06 ÷ 1.20 = 0.05. If the cross-sectional aggregation weight and the axial aggregation weight are 0.40 and 0.60 respectively, the density aggregation coefficient can be 0.05 × 0.40 + 0.05 × 0.60 + 1 = 1.05. The effective cross-sectional area of ​​the reactor discharge pipe is 0.012 square meters, so the volumetric retention rate per unit time is 0.18 × 0.012 = 0.00216 cubic meters per second. Multiplying the volumetric retention rate by the density aggregation coefficient of 1.05, we get a material accumulation rate of 0.002268 cubic meters per second. This allows the material accumulation rate to simultaneously reflect the increased retention due to decreased flow velocity and the enhanced local accumulation due to density aggregation, serving as an input for subsequent clogging trend assessment.

[0086] Step 6018: Read the structural parameters of the reactor discharge pipe; the structural parameters include at least the pipe inner diameter, pipe length, number of bends, size of local narrowing sections, vertical height difference, discharge outlet elevation, and elevation of the connection position with the downstream receiving container; if there are tees, observation ports, or maintenance ports, the corresponding connection position dimensions are also read; the above structural parameters are derived from the discharge pipe design drawings or equipment installation measurement results.

[0087] Step 6019: Read material properties; the material properties include at least the current material density, the current material viscosity, and the foaming coefficient; wherein, the current material density is determined by the average value of the average density of the cross-section at each axial position, the current material viscosity is the window viscosity value, and the foaming coefficient is determined based on the process material data or historical material feeding test records.

[0088] Step 6020: Determine sensitive overflow locations; specifically: first, identify high-elevation points, maintenance openings, connections to downstream receiving containers, and adjacent upstream locations after partial diameter reduction in the reactor discharge pipe, and list these locations as candidate overflow locations; then, determine the corresponding overflow boundary for each candidate overflow location. Specifically, the overflow boundary for high-elevation points is the highest point of the pipe's inner wall at that location; the overflow boundary for maintenance openings is the lowest edge of the maintenance opening; the overflow boundary for connections to downstream receiving containers is the upper boundary of the allowable liquid level at the connection point; and the overflow boundary for adjacent upstream locations after partial diameter reduction is the boundary of the location upstream of the reduced diameter section most prone to backflow. Then, for each... A candidate overflow location is identified, and the upper limit of the allowable pressure corresponding to this location is determined based on the vertical height difference between the candidate overflow location and the corresponding overflow boundary, the frictional resistance and local resistance between the candidate overflow location and the corresponding overflow boundary, and the outlet backpressure condition at the corresponding overflow boundary. The upper limit of the allowable pressure corresponding to this candidate overflow location is determined by adding the outlet backpressure at the corresponding overflow boundary, the static pressure increment formed by the current material density and the vertical height difference, and the pressure drop increment due to resistance between the candidate overflow location and the corresponding overflow boundary. The outlet backpressure is determined based on the gas phase pressure of the downstream receiving container, the connection status with the outside environment, or the backpressure of the downstream pipeline. The static pressure increment is determined based on the current material density... The pressure drop increment is determined by the material density, gravitational acceleration, and vertical height difference. It is based on the pipe length, pipe inner diameter, number of bends, local diameter reduction, current flow rate, and current material viscosity between the candidate overflow location and the corresponding overflow boundary. Then, based on the pressure sensor sampling values ​​located at or near the candidate overflow location, and combined with the pipe segment pressure drop relationship between the candidate overflow location and the corresponding pressure sensor, the current pressure estimate for that candidate overflow location is determined. Specifically, when a pressure sensor is directly located at the candidate overflow location, the real-time sampling value of that pressure sensor is used to determine the current pressure estimate; when no pressure sensor is directly located at the candidate overflow location, the pressure estimate is determined by the nearby upstream pressure sensor. The current pressure estimate for a candidate overflow location is determined by subtracting the pipe pressure drop between the upstream pressure sensor and the candidate overflow location from the sensor's sampled value, or by adding the pipe pressure drop between the candidate overflow location and the downstream pressure sensor to the sampled value from the adjacent downstream pressure sensor. The pipe pressure drop is determined based on the length, inner diameter, local resistance structure, current flow rate, and current material viscosity of the corresponding pipe segment. Then, the current pressure estimate for the candidate overflow location is subtracted from the upper limit of the allowable pressure corresponding to the candidate overflow location to obtain the pressure margin for that candidate overflow location. Finally, the pressure margins obtained for each candidate overflow location are compared, and the candidate overflow location with the smallest pressure margin is selected as the overflow sensitive location.

[0089] Step 6021, determine the overflow critical pressure; specifically: read the overflow sensitive location and determine the upper limit of the allowable pressure corresponding to the overflow sensitive location as the overflow critical pressure of the current reactor discharge pipeline; during the subsequent discharge process, when the real-time pipeline pressure value approaches or reaches the overflow critical pressure, it is determined that there is an overflow risk in the current discharge process, and the overflow critical pressure is output to the subsequent steps to jointly determine the overflow pressure margin and blockage overflow prevention status with the real-time pipeline pressure value.

[0090] Step 6022: When there are multiple candidate overflow locations, calculate the critical pressure value of each candidate overflow location and take the minimum value as the overflow critical pressure of the current reactor discharge pipe; the reason is that the location that first reaches the overflow condition determines the upper limit of the overall overflow risk under the current operating conditions.

[0091] Step 6023 outputs the material accumulation rate and overflow critical pressure to subsequent steps to determine the blockage overflow prevention status.

[0092] In some implementations, the purpose of determining the blockage and overflow prevention status based on the material accumulation rate and overflow critical pressure is to convert the material accumulation rate and overflow critical pressure into the risk status result of the current discharge process, so that subsequent discharge control parameter updates no longer depend on a single flow rate or a single pressure, but are based on both blockage and overflow trends simultaneously; the implementation steps include: Step 7011: Read the material accumulation rate and overflow critical pressure, and simultaneously read the real-time pipeline pressure value in the current adjusted monitoring window; the real-time pipeline pressure value is taken from the pressure sampling results of the reactor environment sensor on the corresponding pipe section at the overflow sensitive location; when the overflow sensitive location is not directly equipped with a pressure sensor, the real-time pipeline pressure value at that location is calculated based on the sampling values ​​of adjacent pressure measuring points and the pipeline pressure drop relationship.

[0093] Step 7012: Construct the accumulation rate judgment threshold; specifically: read the upper quantile value of the material accumulation rate distribution in the historical unblocked discharge records, read the lower quantile value of the material accumulation rate distribution in the historical discharge records before blockage, and then add the safety correction amount determined according to the allowable deposition growth rate of the reactor discharge pipeline to obtain the accumulation rate judgment threshold.

[0094] Step 7013: Compare the material accumulation rate with the accumulation rate determination threshold; when the material accumulation rate is less than the accumulation rate determination threshold, determine the blockage trend indicator as 0; when the material accumulation rate is greater than or equal to the accumulation rate determination threshold, determine the blockage trend indicator as 1.

[0095] Step 7014: Calculate the overflow pressure margin; the overflow pressure margin is equal to the overflow critical pressure minus the real-time pipeline pressure value; the smaller the overflow pressure margin, the closer the current real-time pipeline pressure is to the critical pressure at the location that may cause an overflow.

[0096] Step 7015: Construct the overflow pressure margin judgment threshold; specifically: read the lower quantile value of the minimum pressure margin distribution at the overflow sensitive location in the historical safe material discharge record, and combine it with the pressure sensor measurement error and the advance amount of the equipment safety protection action to obtain the overflow pressure margin judgment threshold.

[0097] Step 7016: Compare the overflow pressure margin with the overflow pressure margin judgment threshold; when the overflow pressure margin is greater than the overflow pressure margin judgment threshold, determine the overflow trend indicator as 0; when the overflow pressure margin is less than or equal to the overflow pressure margin judgment threshold, determine the overflow trend indicator as 1.

[0098] Step 7017: Determine the blockage and overflow prevention status based on the combination of the blockage trend indicator and the overflow trend indicator; when the blockage trend indicator is 0 and the overflow trend indicator is 0, the blockage and overflow prevention status is determined to be the normal prevention status; when the blockage trend indicator is 1 and the overflow trend indicator is 0, the blockage and overflow prevention status is determined to be the blockage prevention status; when the blockage trend indicator is 0 and the overflow trend indicator is 1, the blockage and overflow prevention status is determined to be the overflow prevention status; when the blockage trend indicator is 1 and the overflow trend indicator is 1, the blockage and overflow prevention status is determined to be the combined blockage and overflow prevention status.

[0099] Step 7018: Output the blockage and overflow prevention status to subsequent steps to update the discharge control parameters and continuously perform discharge adjustment.

[0100] In some implementations, the discharge control parameters are updated based on the blockage and overflow prevention status, and discharge adjustment is continuously performed based on the updated discharge control parameters to output a stable discharge speed control result. The purpose is to convert the blockage and overflow prevention status into a differentiated discharge control parameter update scheme, and by cyclically executing the above steps, gradually converge the valve opening, adjustment step size, holding time, and reassessment cycle to a stable operating condition, ultimately outputting a stable discharge speed control result. The implementation steps include: Step 8011: Read the blockage and overflow prevention status, and simultaneously read the current actual valve opening value, current speed runaway risk coefficient, current material accumulation rate, and current overflow pressure margin, which will be used as inputs for the current round of parameter updates.

[0101] Step 8012: Construct a set of discharge control parameters; the set of discharge control parameters includes at least the upper limit of the target valve opening, the lower limit of the target valve opening, the single opening correction step size, the opening correction holding time, and the re-evaluation cycle; wherein, the single opening correction step size is used to limit the range of valve opening change in one adjustment, the opening correction holding time is used to limit the duration of maintaining the valve opening value after one adjustment, and the re-evaluation cycle is used to limit the time interval for re-executing material viscosity data, valve opening change data and pipeline flow data acquisition, flow rate instability index determination, pressure abnormal change characteristics and temperature response delay characteristics extraction, velocity runaway risk coefficient calculation, dynamic adjustment of valve opening parameters, material accumulation rate and overflow critical pressure determination, and blockage overflow prevention status determination.

[0102] Step 8013: When the blockage overflow prevention state is the normal prevention state, keep the current actual valve opening value unchanged, set the single opening correction step size to the standard step size, set the opening correction holding time to the standard holding time, and set the re-evaluation cycle to the standard re-evaluation cycle; the standard step size, standard holding time, and standard re-evaluation cycle are determined based on the statistical results of stable working conditions in the historical qualified material discharge records.

[0103] Step 8014: When the blockage overflow prevention state is the blockage prevention state, under the premise of not exceeding the upper limit of the target valve opening, the current actual valve opening value is increased step by step according to the first correction step, and the re-evaluation cycle is shortened to the first re-evaluation cycle; the first correction step is larger than the standard step, and the first re-evaluation cycle is smaller than the standard re-evaluation cycle; its formation is based on the average opening increment and the shortest effective confirmation cycle required to increase the flow rate under historical blockage warning conditions.

[0104] Step 8015: When the blockage overflow prevention state is the overflow prevention state, under the premise of not being lower than the target valve opening lower limit, the current valve actual opening value is gradually reduced according to the second correction step size, and the opening correction holding time is extended to the second holding time; the second correction step size is greater than the standard step size, and the second holding time is greater than the standard holding time; the basis for its formation is the average opening reduction required to suppress pressure and the holding time required to stabilize pressure under historical high pressure overflow warning conditions.

[0105] Step 8016: When the blockage and overflow prevention status is a combined blockage and overflow prevention status, first execute the overflow suppression update, then execute the blockage mitigation update; specifically: first, under the premise of not falling below the target valve opening lower limit, gradually reduce the current valve actual opening value with the third correction step size until the overflow pressure margin is restored to above the overflow pressure margin judgment threshold; then, in at least one subsequent re-evaluation cycle, gradually adjust the valve opening value with the fourth correction step size, and after each adjustment, re-execute the determination of the real-time discharge flow rate based on the adjusted valve opening value and material distribution density change. The material accumulation rate is determined based on the real-time discharge flow rate, the overflow critical pressure is determined based on the structural parameters of the reactor discharge pipeline and the material properties, and the blockage overflow prevention status is determined based on the material accumulation rate and the overflow critical pressure. If the material accumulation rate decreases after the pullback and the overflow pressure margin remains above the threshold, the pullback result is retained. If the overflow pressure margin decreases below the threshold again after the pullback, the pullback is canceled and the valve opening value is restored to the previously confirmed value. The fourth correction step is smaller than the first correction step to avoid rapid pullback causing another overflow under complex risk conditions.

[0106] Step 8017: Based on the updated discharge control parameters from steps 8013 to 8016, send the corresponding valve opening command to the valve actuator and maintain the valve opening value within the updated opening correction holding time. After the holding time ends, according to the updated re-evaluation cycle, re-execute the following processes: discharge status acquisition, flow rate instability analysis, environmental interference feature extraction, velocity runaway risk coefficient calculation, valve opening dynamic adjustment, material accumulation rate and overflow critical pressure determination, and blockage overflow prevention status determination.

[0107] Step 8018: Construct stable discharge judgment conditions. The stable discharge judgment conditions include at least the following: the flow rate instability index is 0 for at least three consecutive reassessment cycles; the velocity runaway risk coefficient is lower than the low-risk threshold for at least three consecutive reassessment cycles; the blockage overflow prevention status is normal prevention status for at least three consecutive reassessment cycles; the deviation of the real-time discharge flow rate from the accumulated reference flow rate is within the allowable deviation range for at least three consecutive reassessment cycles; the low-risk threshold is determined based on the upper limit of the risk coefficient distribution in the historical qualified discharge records, and the allowable deviation range is determined based on the target discharge accuracy set by the process.

[0108] Step 8019: If the stable discharge determination condition is not met, continue executing the loop process corresponding to step 8017; if the stable discharge determination condition is met, output a stable discharge speed control result; the stable discharge speed control result includes at least the final valve opening value, the set of discharge control parameters corresponding to the final valve opening value, the real-time discharge flow rate range in the stable state, and the confirmation result that the corresponding blockage overflow prevention state is a normal prevention state. This completes the entire process of updating the discharge control parameters based on the blockage overflow prevention state and continuously executing discharge adjustment.

[0109] In some implementations, to illustrate the process of updating the discharge control parameters corresponding to the blockage overflow prevention state, if step 7013 determines the blockage trend indicator to be 1 and step 7016 determines the overflow trend indicator to be 0, then the blockage overflow prevention state can be determined as the blockage prevention state. The current actual valve opening value can be 43.2%, the target valve opening upper limit can be 58.0%, the standard step size can be 1.0%, the first correction step size can be 2.0%, the standard re-evaluation cycle can be 20 seconds, and the first re-evaluation cycle can be 10 seconds. Then, without exceeding the target valve opening upper limit, the current actual valve opening value is increased from 43.2% to 45.2%, and after 10 seconds, the acquisition of material viscosity data, valve opening change data, and pipeline flow data, determination of flow rate instability indicators, calculation of velocity runaway risk coefficient, dynamic adjustment of valve opening parameters, determination of material accumulation rate, and determination of the blockage overflow prevention state are re-executed. If the material accumulation rate drops below the accumulation rate judgment threshold in the next reassessment cycle, and the overflow pressure margin remains above the overflow pressure margin judgment threshold, the blockage overflow prevention state will be restored to the normal prevention state, and the material discharge adjustment will continue to be executed according to the standard step size, standard holding time, and standard reassessment cycle; if the stable material discharge judgment condition is met continuously, a stable material discharge speed control result will be output.

[0110] Example 2 See Figure 2 As shown, this embodiment provides an automatic control system for the reactor discharge process. Since this system uses an automatic control method for the reactor discharge process in Embodiment 1, it has the same effect, which will not be repeated here. The system includes: The deviation determination module is used to acquire material viscosity data, valve opening change data and pipeline flow data collected by sensors inside the reactor and the reactor discharge pipeline, and compare the material viscosity data with the preset viscosity range to determine the viscosity deviation value. The instability determination module is used to analyze the stability of material flow velocity and determine the instability index based on viscosity deviation value, valve opening change data and flow fluctuation amplitude and flow decrease amplitude in pipeline flow data. The risk assessment module is used to acquire pressure and temperature interference data collected by environmental sensors in the reactor when the flow rate instability index exceeds a preset threshold. Based on the pressure interference data, it determines the characteristics of abnormal pressure changes, and based on the temperature interference data, it determines the characteristics of temperature response delay and stabilization time. Based on the characteristics of abnormal pressure changes, temperature response delay and stabilization time, it calculates the risk coefficient of speed runaway. The valve opening adjustment module is used to dynamically adjust the valve opening parameters based on the speed runaway risk coefficient, pressure abnormal change characteristics, and temperature response delay characteristics, to obtain the adjusted valve opening value and monitor the changes in material distribution density in the pipeline. The prevention and judgment module is used to monitor the discharge flow rate in real time based on the adjusted valve opening value and the change in material distribution density, determine the material accumulation rate based on the discharge flow rate, determine the overflow critical pressure based on the structural parameters of the reactor discharge pipeline and the material properties, and determine the blockage and overflow prevention status based on the material accumulation rate and the overflow critical pressure. The control update module is used to update the discharge control parameters according to the blockage and overflow prevention status, and continuously perform discharge adjustment based on the updated discharge control parameters to output a stable discharge speed control result.

[0111] The above description is merely a specific embodiment of this application, but the scope of protection of this application is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the scope of the technology disclosed in this application should be included within the scope of protection of this application. Therefore, the scope of protection of this application should be determined by the scope defined in the claims.

Claims

1. An automatic control method for the discharge process of a reaction vessel, characterized in that, include: Acquire material viscosity data, valve opening change data, and reactor discharge pipeline flow data collected by sensors inside the reactor. Compare the material viscosity data with the preset viscosity range to determine the viscosity deviation value. Based on viscosity deviation values, valve opening change data, and flow fluctuation and flow decrease in pipeline flow data, analyze the stability of material flow velocity and determine the flow velocity instability index. When the flow rate instability index is higher than the preset threshold, pressure interference data and temperature interference data collected by the reactor environment sensor are acquired. Based on the pressure interference data, the characteristics of abnormal pressure change are determined. Based on the temperature interference data, the characteristics of temperature response delay and stabilization time are determined. Based on the characteristics of abnormal pressure change, temperature response delay and stabilization time, the risk coefficient of speed runaway is calculated. Based on the speed runaway risk coefficient, pressure abnormal change characteristics, and temperature response delay characteristics, the valve opening parameters are dynamically adjusted to obtain the adjusted valve opening value, and the changes in material distribution density in the pipeline are monitored. Based on the adjusted valve opening value and material distribution density changes, the discharge flow rate is monitored in real time, and the material accumulation rate is determined based on the discharge flow rate. The overflow critical pressure is determined based on the structural parameters of the reactor discharge pipeline and the material properties. The blockage and overflow prevention status is determined based on the material accumulation rate and the overflow critical pressure. The discharge control parameters are updated based on the blockage and overflow prevention status, and the discharge adjustment is continuously performed based on the updated discharge control parameters to output a stable discharge speed control result.

2. The automatic control method for the discharge process of a reaction vessel according to claim 1, characterized in that, Methods for determining viscosity deviation values ​​include: Within a fixed analysis window, acquire sampled values ​​of material viscosity, valve opening, and flow rate, and perform validity screening on these sampled values. Window representative values ​​are calculated from multiple material viscosity samples that have passed effectiveness screening to obtain window viscosity values; Based on the target viscosity range in the process document corresponding to the target material, the viscosity distribution of historical qualified batches in the current discharge temperature range, and the maximum allowable viscosity of the reactor discharge pipeline under the current valve specifications and current discharge stage, a preset viscosity range is constructed. The viscosity value in the window is compared with the preset viscosity range to determine the viscosity deviation value.

3. The automatic control method for the discharge process of a reaction vessel according to claim 1, characterized in that, Methods for determining flow velocity instability indicators include: Read viscosity deviation values, valve opening change data, and pipeline flow data of the reactor discharge pipeline, and generate flow time series and velocity time series based on the pipeline flow data; The flow fluctuation amplitude and flow decrease amplitude are determined based on the flow time series, and the response correspondence is determined based on the valve opening change data and the flow velocity time series. The viscosity deviation value, flow fluctuation amplitude, and flow drop amplitude are normalized, and then weighted and summed according to the viscosity deviation weight, flow fluctuation weight, and flow drop weight to obtain the initial flow velocity instability. When the response correspondence is not established, the initial flow velocity instability is corrected according to the preset mismatch compensation amount to obtain the final flow velocity instability. The final degree of flow velocity instability is compared with the flow velocity instability judgment threshold to determine the flow velocity instability index.

4. The automatic control method for the discharge process of a reaction vessel according to claim 3, characterized in that, Methods for identifying the characteristics of abnormal pressure mutations include: When the final flow velocity instability is greater than or equal to the flow velocity instability judgment threshold, the flow velocity instability index is set to 1. When the flow velocity instability index is 1, an environmental analysis window is established, and pressure interference data is obtained within the environmental analysis window. The pressure baseline is determined based on the average pressure value within three consecutive stable windows before the flow rate instability index is triggered, or the reference pressure value corresponding to the current discharge stage. The pressure deviation and pressure change rate are determined based on the pressure disturbance data and pressure baseline; the pressure deviation and pressure change rate are compared with the pressure deviation threshold and pressure change rate threshold, respectively, to identify pressure anomalies and merge them to form pressure anomaly segments. Based on the pressure anomaly segment, the onset time, amplitude, and duration of the pressure anomaly are determined, thus obtaining the characteristics of the pressure anomaly abrupt change.

5. The automatic control method for the discharge process of a reaction vessel according to claim 4, characterized in that, Methods for determining temperature response delay characteristics and settling time include: Acquire temperature disturbance data within the environmental analysis window, and determine the temperature baseline based on the average temperature value within three consecutive stable windows before the flow rate instability index is triggered, or the reference temperature value corresponding to the current discharge stage. Read the valve opening change data and determine the start time of the opening change; The temperature offset is determined based on the temperature interference data and the temperature baseline, and the temperature response start time is determined based on the first sampling time when two or more consecutive temperature offsets reach the temperature response judgment threshold. The temperature response delay value is determined based on the temperature response start time and the opening change start time, and the temperature response delay value is averaged when there are multiple temperature response events to obtain the temperature response delay characteristics. The length of the longest continuous time period is determined based on the temperature stability range and temperature disturbance data, thus obtaining the stability duration.

6. The automatic control method for the discharge process of a reaction vessel according to claim 5, characterized in that, Methods for calculating the risk factor of speed runaway include: Extract the abnormal pressure amplitude, duration of abnormal pressure, temperature response delay, and stabilization time. The magnitude and duration of abnormal pressure are normalized separately, and the pressure risk value is calculated by combining the magnitude weight and the duration weight. The temperature response delay value is normalized to obtain the temperature delay risk value; The temperature stability risk value is obtained by reverse normalization of the stabilization time. The speed runaway risk coefficient is obtained by weighting and summing the pressure risk value, temperature delay risk value, and temperature stability risk value according to their corresponding pressure weights, temperature delay weights, and temperature stability weights. The speed runaway risk coefficient is limited to a certain range to obtain the speed runaway risk coefficient after the range is limited.

7. The automatic control method for the discharge process of a reaction vessel according to claim 1, characterized in that, Methods for obtaining the adjusted valve opening value include: Read the actual valve opening value before adjustment and set the actual valve opening value before adjustment as the current valve opening reference value; The flow deviation is determined based on the baseline flow value used to determine the magnitude of the flow drop and the average flow value within the current analysis window. The valve opening adjustment direction is then determined based on the flow deviation, the abnormal pressure amplitude, and the high pressure limit threshold. The basic opening correction amount is determined based on the speed runaway risk coefficient. Pressure correction and temperature delay correction are then applied sequentially to the basic opening correction amount to obtain the opening correction amount after delay correction. The adjusted valve opening value is calculated based on the current valve opening reference value, the valve opening adjustment direction, and the opening correction amount after delay correction, and boundary limits are applied to the adjusted valve opening value.

8. The automatic control method for the discharge process of a reaction vessel according to claim 7, characterized in that, Methods for determining material accumulation rate and overflow critical pressure include: The adjusted flow rate sequence is obtained based on the adjusted valve opening value, and the real-time discharge flow rate is determined based on the adjusted flow rate sequence and the effective cross-sectional area of ​​the reactor discharge pipe. The velocity gap value is determined based on the baseline flow rate and the real-time discharge velocity, and the density aggregation coefficient is determined in combination with the material distribution density change. The material accumulation rate is determined based on the velocity gap value, the effective cross-sectional area of ​​the reactor discharge pipe, and the density aggregation coefficient. Read the structural parameters and material properties of the reactor discharge pipe, determine the upper limit of allowable pressure and the current pressure estimate corresponding to the candidate overflow location, determine the overflow sensitive location based on the pressure margin of each candidate overflow location, and determine the overflow critical pressure based on the upper limit of allowable pressure corresponding to the overflow sensitive location.

9. The automatic control method for the discharge process of a reaction vessel according to claim 8, characterized in that, Methods for outputting stable material feeding speed control results include: Read the blockage and overflow prevention status and construct the discharge control parameters, including the target valve opening upper limit, target valve opening lower limit, single opening correction step size, opening correction hold duration and re-evaluation cycle; Update the material discharge control parameters according to whether the blockage and overflow prevention status is normal prevention status, blockage prevention status, overflow prevention status, or a combination of blockage and overflow prevention status; Based on the updated discharge control parameters, valve opening commands are sent, and after the opening correction holding time ends, the discharge status acquisition, flow rate instability analysis, environmental interference feature extraction, speed runaway risk coefficient calculation, valve opening dynamic adjustment, material accumulation rate and overflow critical pressure determination, and blockage overflow prevention status determination are re-executed according to the re-evaluation cycle. When the stable feeding judgment condition is met, a stable feeding speed control result is output.

10. An automatic control system for a reactor discharge process, used to implement the automatic control method for a reactor discharge process according to any one of claims 1-9, characterized in that, The system includes: The deviation determination module is used to acquire material viscosity data, valve opening change data and pipeline flow data collected by sensors inside the reactor and the reactor discharge pipeline, and compare the material viscosity data with the preset viscosity range to determine the viscosity deviation value. The instability determination module is used to analyze the stability of material flow velocity and determine the instability index based on viscosity deviation value, valve opening change data and flow fluctuation amplitude and flow decrease amplitude in pipeline flow data. The risk assessment module is used to acquire pressure and temperature interference data collected by environmental sensors in the reactor when the flow rate instability index is higher than a preset threshold. Based on the pressure interference data, it determines the characteristics of abnormal pressure changes, and based on the temperature interference data, it determines the characteristics of temperature response delay and stabilization time. Based on the characteristics of abnormal pressure changes, temperature response delay and stabilization time, it calculates the risk coefficient of speed runaway. The valve opening adjustment module is used to dynamically adjust the valve opening parameters based on the speed runaway risk coefficient, pressure abnormal change characteristics, and temperature response delay characteristics, to obtain the adjusted valve opening value and monitor the changes in material distribution density in the pipeline. The prevention and judgment module is used to monitor the discharge flow rate in real time based on the adjusted valve opening value and the change in material distribution density, determine the material accumulation rate based on the discharge flow rate, determine the overflow critical pressure based on the structural parameters of the reactor discharge pipeline and the material properties, and determine the blockage and overflow prevention status based on the material accumulation rate and the overflow critical pressure. The control update module is used to update the discharge control parameters according to the blockage and overflow prevention status, and continuously perform discharge adjustment based on the updated discharge control parameters to output a stable discharge speed control result.

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